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Home >> Chevrolet >> 2003 >> Malibu Base >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling System >> Repair Instructions >> Radiator Replacement >> Removal Procedure

Removal Procedure

  1. Remove the battery. Refer to BATTERY REPLACEMENT in Engine Electrical.
  2. Remove the battery tray.
  3. Recover the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation, and Air Conditioning.
  4. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
  5. Use the J 38185  in order to reposition the upper radiator hose and clamps.
  6. Remove the upper radiator hose.
  7. Remove the upper transaxle cooler line.
  8. Use the J 38185  in order to reposition the surge tank hose and clamps from the surge tank.
  9. Remove the coolant surge tank hose.
  10. Remove the condenser inlet fitting from the discharge hose.
  11. Disconnect the cooling fan electrical connector.
  12. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  13. Remove the lower closeout panel.
  14. Use the J 38185  in order to reposition the lower radiator hose from the radiator.
  15. Remove the lower radiator hose from the radiator.
  16. Remove the lower transaxle cooler line.
  17. Remove the evaporator line from the condenser outlet.
  18. Remove the lower radiator mounting panel.
    Fig 1: Removing Radiator, Fan & Condenser As Assembly
    G01514390Courtesy of GENERAL MOTORS CORP.
  19. Remove the radiator, fan and condenser as an assembly from the vehicle.
  20. Remove the condenser from the radiator.
  21. Remove the fan shroud from the radiator.
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